Lecture 9 - Hen III - PDM

Heat exchanger network III Heat exchanger network III Heat exchanger network III Heat exchanger network
III Pinch Pinch Pinch Pinch

design method & network evolution design method & network evolution design method & network evolution design method & network evolution
Copyright@Dominic Foo H82PLD - Plant Design PDM - 2
Lecture outline Lecture outline Lecture outline Lecture outline
The grid diagram for HEN design
The pinch design method (PDM)
Minimum unit targeting
Stream splitting
Network evolution
Heuristics for HEN design Heuristics for HEN design Heuristics for HEN design Heuristics for HEN design
No individual heat exchanger should have a temp
difference < than T
min
To achieve energy targets, must not transfer heat across the
pinch by:
Process-process heat transfer
Inappropriate use of utility
T
min
Cost
Total
Energy
Capital
The composite curves The composite curves The composite curves The composite curves
H (MW)
T (C)
T
min
Pinch
Q
Hmin
Q
Cmin
Heat
sink
Heat
source
Heat transfer across pinch Heat transfer across pinch Heat transfer across pinch Heat transfer across pinch
H (MW)
T (C)
Q
Hmin
+XP
Q
Cmin
+XP
Heat
sink
Heat
source
XP
Don Don Don Don t cold above the pinch t cold above the pinch t cold above the pinch t cold above the pinch
H (MW)
T (C)
Q
Hmin
+XP
Q
Cmin
Heat
sink
Heat
source XP
Don Don Don Don t heat below the pinch t heat below the pinch t heat below the pinch t heat below the pinch
H (MW)
T (C)
Q
Hmin
Q
Cmin
+XP
Heat
sink
Heat
source
XP
Let Let Let Let s design together s design together s design together s design together while while while while
we go along we go along we go along we go along
Back to the previous example Back to the previous example Back to the previous example Back to the previous example
30.0
27.0
31.5
32.0
H
(MW)
0.20 180 20 Cold 1. Reactor 1 feed
0.15 40 250 Hot 2. Reactor 1 product
0.25 80 200 Hot 4. Reactor 2 product
0.30 230 140 Cold 3. Reactor 2 feed
Heat capacity
flowrate, CP
(MW.K
-1
)
Target
temp,
T
T
(C)
Supply
temp,
T
S
(C)
Type Steam
Reactor 1
Feed 1
20C
Reactor 2
Feed 2
140C
Off gas, 40C
Product 1, 40C
180C
40C
250C
230C 200C Product 2
80C
Note: Heat capacity flowrate, CP = m.C
p
( )
S T p p
T T mC T mC Q = =
The grid diagram The grid diagram The grid diagram The grid diagram
To comply with the rules, process should be
divided at the pinch
The grid diagram:
2
4
1
3
Above pinch Below pinch
CP
(MW/C)
0.15
0.25
0.20
0.30
Pinch
Q
H, min
= 7.5 MW Q
C, min
= 10 MW
250
200
180
230
150
150
140
140
40
80
20
H
(MW)
31.5
30.0
32.0
27.0
The pinch design method (PDM) The pinch design method (PDM) The pinch design method (PDM) The pinch design method (PDM)
1. Start design at the pinch
Pinch is the most constrained region of the network
At the pinch, T
min
exists between all hot & cold
streams number of feasible matches is limited
Start design at the pinch avoid trouble in stream
matching at later stage
2. The CP inequality for individual match
Above pinch: CP
H
CP
C
Below pinch: CP
H
CP
C
3. The CP table
4. The tick-off heuristic
CP inequality CP inequality CP inequality CP inequality
H (MW)
T (C)
T
min
Pinch
Above pinch:
CP
H
CP
C
Below pinch:
CP
H
CP
C
CP inequality CP inequality CP inequality CP inequality
Note:
Only apply at the pinch & when both end of the match are at pinch
conditions
Away from the pinch, temp differences increase no longer
essential to obey CP inequalities
Above pinch:
CP
H
CP
C
Below pinch:
CP
H
CP
C
Generalisation:
CP
out
CP
in
2
4
1
3
Above pinch
Below pinch
Pinch
250
200
180
230
150
150
140
140
40
80
20
The CP table The CP table The CP table The CP table
2
4
1
3
Above pinch
CP
0.15
0.25
0.20
0.30
Pinch
250
200
180
230
150
150
140
140
2
4
1
Below pinch
CP
0.15
0.25
0.20
Pinch
150
150
140
0.3 0.25
0.2 0.15
CP
H
CP
C
0.2 0.25
0.15
CP
H
CP
C CPs in
descending
order
40
80
20
The The The The tick tick tick tick- -- -off off off off heuristic heuristic heuristic heuristic
Minimum number of heat exchanger units leads to
reduced capital cost achieved by tick-off
heuristic
Individual units are made as large as possible, i.e.
smaller of the 2 heat duties on the matched stream
Tick-off the stream where heat is fully recovered
Proceed to other streams away from pinch
Complete the design with hot & cold utility:
Only use hot utility above the pinch
Only use cold utility belowthe pinch
Region above the pinch Region above the pinch Region above the pinch Region above the pinch
2
4
1
3
CP
0.15
0.25
0.20
0.30
Pinch
250
200
180
230
150
150
140
140
H
15.0
12.5
8.0
27.0
12.5
8.0
203.3
H
205
7.5 7.0
181.7
14.5
7.5
7
Region below the pinch Region below the pinch Region below the pinch Region below the pinch
2
4
CP
0.15
0.25
0.20 1
Pinch
150
150
140
40
80
20
H
16.5
17.5
24.0
17.5 6.5
C
10.0
52.5
106.7
6.5
10
A complete network A complete network A complete network A complete network
Utility targets matched
(refer to CC & PTA for this
problem in earlier lecture)
1
3
Pinch
250
200
180
230
150
150
140
140
12.5
8.0
H
7.5 7.0
2
4
17.5 6.5
C
10.0
40
80
20
Some remarks on PDM Some remarks on PDM Some remarks on PDM Some remarks on PDM
Tick-off heuristic occasionally may cause problem, be aware
Minimum number of heat exchanger units:
The tick-off heuristic of PDM steers the network design towards
the minimum number of heat exchanger units
The stream that has been ticked-off is no longer part of the
remaining design problem ensures that a stream is removed
from the problem once a unit is placed.
General steps of PDM:
Divide the region at the pinch (i.e. above/below pinch)
Start design at the pinch, moving away.
At the pinch, temp feasibility requires that CP
out
CP
in
Loads of heat exchangers are determine by using tick-off heuristic.
Away from pinch, design is more flexible consider other
practical factors, e.g. operability, plant layout, etc.
Number of heat exchange units Number of heat exchange units Number of heat exchange units Number of heat exchange units
Minimum number of heat exchanger in a HEN:
N
units
= S 1
where S = number of streams including utilities
Due to the existence of the pinch point, unit targets is
applied to both sides of the pinch:
N
units
= [S
Above pinch
1] + [S
Below pinch
1]
The grid diagram:
1
2
3
4
CW
Steam
Above pinch
Below pinch
N
units
= (5 1) + (4 1) = 7
Pinch
The highway analogy The highway analogy The highway analogy The highway analogy
Kajang KL
Semenyih
Kajang KL
Semenyih Putrajaya
Kajang KL
Semenyih
Putrajaya
KLIA
What is the
minimum no of
road needed to
connect all cities?
Do we have min # of HX? Do we have min # of HX? Do we have min # of HX? Do we have min # of HX?
1
3
250
200
180
230
150
150
140
140
12.5
8.0
H
7.5 7.0
2
4
17.5 6.5
C
10.0
40
80
20
N
units
= (4 1) + (5 1) = 7
Working session Working session Working session Working session
Design a HEN for maximum recovery that feature the
minimum number of units.
Targeting from PTA:
Q
H,min
= 15 MW
Q
C,min
= 26 MW
T
min
= 20C:
Hot pinch temp = 120C
Cold pinch temp = 100C
0.6
0.4
0.5
0.3
Heat capacity
flowrate, CP
(MW.K
-1
)
60 400 Hot 1.
40 210 Hot 2.
300 100 Cold 4.
160 20 Cold 3.
H
(MW)
Target temp,
T
T
(C)
Supply temp,
T
S
(C)
Type Steam
Min # of HX units Min # of HX units Min # of HX units Min # of HX units
3
400
210
160
300
1
2
60
40
20
4
100
N
units
= _____ + _____ = ____
Complete network Complete network Complete network Complete network
3
400
210
160
300
1
2
60
40
20
4
100
Practice makes perf Practice makes perf Practice makes perf Practice makes perfect! ect! ect! ect!
Stream splitting Stream splitting Stream splitting Stream splitting
The PDM allows for minimum utility (or maximum
energy recovery) using minimum number of
units.
Stream splitting needs to be considered in the
following situations:
Number of streams at the pinch
CP inequality cannot be met at the pinch
Number of streams above pinch Number of streams above pinch Number of streams above pinch Number of streams above pinch
4
5
90
90
1
2
Pinch
100
100
3
100
?
T > 90
T > 90
4
5
90
90
1
2
Pinch
100
100
3
100
Number of streams below pinch Number of streams below pinch Number of streams below pinch Number of streams below pinch
3
90
1
2
Pinch
100
100
90
90
4
5
?
T < 100
T < 100
3
90
1
2
Pinch
100
100
90
90
4
5
T < 100
T < 100
CP inequality above pinch CP inequality above pinch CP inequality above pinch CP inequality above pinch
CP
H
CP
C
2
3 4
5
3
S
H
S
C
Above pinch
1
2
3
CP
5
4
3
Pinch
100
90
90
3
CP
H
CP
C
4
5
S
H
S
C
Above pinch
3 1
2
3
CP
4
3
Pinch
100
90
90
2
CP inequality below pinch CP inequality below pinch CP inequality below pinch CP inequality below pinch
7
CP
H
CP
C
4 5
3 4
S
H
S
C
1
2
3
Below pinch
CP
5
4
7
Pinch
100
100
90
CP
H
CP
C
7
5
4
S
H
S
C
Below pinch
3
1
2
3
CP
5
4
Pinch
100
100
90
4
Remark: New CP values may vary, so long as CP inequalities are satisfied.
Stream splitting algorithms Stream splitting algorithms Stream splitting algorithms Stream splitting algorithms
Split out
stream
Split in
stream
Place
matches
Stream data
at pinch
CP
out
CP
in
for pinch
matches?
N
out
N
in
?
Yes Yes
No
No
Design a HEN for maximum recovery that feature the
minimum number of units.
Targeting from PTA:
Q
H,min
= 9.2 MW
Q
C,min
= 6.4 MW
T
min
= 20C:
Hot pinch temp = 520C
Cold pinch temp = 500C
0.02
0.043
0.040
0.045
Heat capacity
flowrate, CP
(MW.K
-1
)
320 720 Hot 1.
220 520 Hot 2.
550 200 Cold 4.
900 300 Cold 3.
H
(MW)
Target temp,
T
T
(C)
Supply temp,
T
S
(C)
Type Steam
Complete network Complete network Complete network Complete network
3
4
720
520
900
550
1
2
320
220
300
200
N
units
= _____ + _____ = ____
Network optimisation Network optimisation Network optimisation Network optimisation
None of the heat exchangers in a HEN synthesised
by PDM should have a temp difference < T
min
.
Once a HEN is synthesised, it can undergo
continuous optimisation, the constraints of no heat
exchangers having temp difference < T
min
can be
relaxed (pinch is ignored).
Heat exchanger duties will be redistributed:
Some become bigger
Some become smaller or removed (new duty = 0)
Useful tools:
Utility paths lines that connects between 2 utilities
Heat loops path that begins & ends at the same point
Heat loops Heat loops Heat loops Heat loops
2
4
3
Pinch is
ignored
250
200
180
230
H
1
40
80
20
U +U
U +U
Heat loop
C
Heat loops Heat loops Heat loops Heat loops
2
4
3
250
200
180
230
H
1
40
80
20
Heat loop
C
V
V
V
V
+V
+V
+V
+V
Utility paths Utility paths Utility paths Utility paths
2
4
3
250
200
180
230
H
1
40
80
20
C
+W
+W
W
W
Utility path
Utility paths Utility paths Utility paths Utility paths
2
4
3
250
200
180
230
H
1
40
80
20
C
X
+X
Utility path
+X
X
X +X
+X
X
Some remarks Some remarks Some remarks Some remarks
For heat exchanger with new heat duty = 0, the exchanger is
removed from the network
During optimisation, design is no longer constrained to
have temp difference > T
min
(very small T
min
should be
avoided for practical reasons)
Pinch no longer divides design in independent
thermodynamic regions (above & below pinch) main
concern is to reduce cost
Heat loops, utility paths & stream splits offer degree of
freedom for manipulating network cost
To optimise network:
At fixed energy consumption: loops & stream splits
Varying energy consumption is allowed: include utility paths
Evolve the HEN designed earlier by PDM to
simplify its structure:
Remove smallest unit from the network by exploiting
degree of freedom in a loop
Recalculate the network temp & identify any violations
of T
min
= 10C constraint
Restore the original T
min
= 10C throughout the
network by exploiting a utility path

Lecture 9 - Hen III - PDM

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III Pinch Pinch Pinch Pinch

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